SPORTSMAN 700 Model #A02CH68(AA)(AB)(AC) Model #A02CH68(CA)(CB) Rev. 02

Transcription

1 SPORTSMAN 00 Model #A0CH(AA)(AB)(AC) Model #A0CH(CA)(CB) Rev. 0 E 00 Polaris Sales Inc. PARTS MANUAL PN and MICROFICHE PN /0

2 TABLE OF CONTENTS SPORTSMAN 00 A0CH(AA)(AB)(AC) and SPORTSMAN 00 A0CH(CA)(CB) Parts Manual A -ARM/STRUT MOUNTING... AIR BOX... BRAKE LINE... BRAKE, FRONT... BUMPER MOUNTING... A B C B B B0 B A CAB, FRONT... A CAB,REAR... A- CABLE... B CALIPER, REAR... C CARBURETOR... D- CLUTCH COVER... C CONTROLS - MASTER CYLINDER/BRAKE LINE... B0 CONTROLS - THROTTLE ASM./CABLE... B COOLING SYSTEM... A0 CRANKCASE... D CRANKSHAFT... D CYLINDER... D- CYLINDER HEAD... D- DECALS... DRIVE CLUTCH... DRIVE SHAFT, FRONT... DRIVE SHAFT, REAR... DRIVEN CLUTCH... D A C B B C GEARCASE (INTERNAL COMPONENTS)... C- HANDLEBAR... B- HEADLIGHT POD... B- INTAKE H... I M MAGNETO... MASTER CYLINDER... MASTER CYLINDER, REAR... OIL PUMP O... PISTON... PROP SHAFT, FRONT... PROP SHAFT, REAR... P R D D B0 C D D B B RACK MOUNTING, FRONT... A- RACK MOUNTING, REAR (If Built Before /0/0)... A RACK MOUNTING, REAR (If Built After /0/0)... E REAR WHEEL DRIVE... C ELECTRICAL... C ENGINE MOUNTING... A- EXHAUST... D EXHAUST SYSTEM... A FRAME... A- FRONT HOUSING... C FUEL TANK... A GEAR SELECTOR E F G... C0 G GEARCASE (Cases and Snorkel)... D- SEAT... A- STARTING MOTOR... D STEERING POST... B STRUT, FRONT... B SUSPENSION, REAR... C- TAILLIGHT... THROTTLE ASM.... TOOL KIT... TRANSMISSION MOUNTING... S T W C B E C WATER PUMP... D WHEEL, FRONT... B The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

3 REAR CAB, SEAT and MAIN FRAME SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB E 00 Polaris Sales Inc A

4 REAR CAB, SEAT and MAIN FRAME SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Rivet, T-Lock Nut, Nylok Washer 0 Foil, Rear Cab, Rear Cab, Rear, Black Met (AA)(CA)(CB) Cab, Rear, Yellow (AC) Cab, Rear, Spruce (AB) 0 Bolt 0 Retainer, Seat Latch 00 Decal, Stroke, Carb/Filter Information 0 Foil, Tape, Rear Cab 0 Screw Washer, Flat 0 Screw Box, Tool Screw 0 Rivet 0 Bracket, Lever Retainer 00 Latch, Seat 00 Spring, Latch Asm.,Seat,Black Covering, Seat, Black 0 0 Bumper, Rubber Cover, Tool Box 0 Cap, Drain Rivet -0 Guard, Clutch (If built before //0) Nut Screw -0 Brace, Frame 0-0 Frame, Main Nut, Nylok 0 Mount, Rubber (LH Side Only)(AA)(CA)(CB) 0 Spacer Screw 0 00 Decal, Hitch (CB)(AA CA If built before 0//0) Decal, Hitch (AB)(AC)(AA CA If built after 0//0) Screw Foil, Rear Fender 0 Foil 0 Foil, Rear Cab, Front Guard, Mud, Rear, LH Guard, Mud, Rear, RH 00 Nut, U-Type Speed 0 Screw (LH Side) Screw (RH Side) Footwell, Black, LH Footwell, Black, RH Bracket, Reservoir /0 A

5 FRONT CAB SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Foil, Side Panel, Gen. IV, RH Panel, Side, Gun Metal, LH (AA)(CA)(CB) Panel/Foil, Gun Metal, RH (AA)(CA)(CB) Panel, Side, Yellow, LH (AC) Panel/Foil, Yellow, RH (AC) Panel, Side, Spruce, LH (AB) Panel/Foil, Spruce, RH (AB) Foil, Side Panel, RH Screw Cab, Front, Black Met (AA)(CA)(CB) Cab, Front, Yellow (AC) Cab, Front, Spruce (AB) 00 Nut, U-Type Speed Cover, Front, Black Met (AA)(CA)(CB) Cover, Front, Yellow (AC) 0- Cover, Front, Spruce (AB) Screw 0 Nut, Push-on 0 Screw -0 Strap, Fuel Pump (If built before //0) 0-0 Guard, Splash, RH Washer, Flat Nut, Nylok Guard, Mud, Front, Black, LH Guard, Mud, Front, Black, RH Nut, Nylok Washer 0 Screw /0 A

6 REAR RACK MOUNTING (If Built Before /0/0) SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB (Built after /0/0) 0 0 Kit, Rack Extender, Rear (Incl. ) Screw Screw 0-00 Asm., Rack, Rear (Incl. Ref. and Warning Decal) 0 Decal, Reflector, Red Nut, Nylok 0 Washer, Flat Mount, Front, Rear Rack, LH (If built before /0/0) Mount, Front, Rear Rack, RH (If built before /0/0) Screw 0-0 Spacer (If built before /0/0) 00 Nut, Chimney (If built before /0/0) Support, Rear Rack (If built before /0/0) Support, Rear Rack (If built after /0/0) 0 Screw 0 Spacer (If built built after /0/0) Screw (If built built after /0/0) /0 A

7 FRONT RACK and BUMPER MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB A

8 FRONT RACK and BUMPER MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB -0 Kit, Front Rack Extender Screw Asm., Front Rack (Incl. Ref. and Warning Decal) 0 Decal, Reflector, Amber Screw Support, Front Rack, LH Support, Front Rack, RH Headlight, LH Headlight, RH Bulb, Replacement, W Nut, Nylok 0 Nutsert 0 Screw Insert Washer, Flat 0 Screw Support, Front Rack (AB)(AC) Support, Front Rack (AA)(CA)(CB) Bumper 0 Washer, Flat 0 Screw Panel 0 Screw 0 Screw 0-0 Guard, Brush 0 Screw 00 Nut, U-Type Shield, Side, Radiator, LH Shield, Side, Radiator, RH 0 Grommet Cover, Radiator 0-0 Grill 0 0 Screw (If built before //0) Screw (If built after //0) -0 Bracket, Bumper, Lower /0 A

9 DECALS SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 RH 0 LH 00 Decal, Warning, Front/Rear Rack Decal, Side Panel Fade, LH (AA)(CA)(CB) Decal, Side Panel Fade, RH (AA)(CA)(CB) 0 Urocal, X On Demand True WD 0 Decal, Age Warning 00 Decal, Warning AWD Switch 00 Decal Ignition 000 Decal, Headlight Adjustment Decal, Tank Side, 00 TWIN, LH (AA)(CA)(CB) Decal, Tank Side, 00 TWIN, RH (AA)(CA)(CB) Decal, Tank Side (AC) Decal, Tank Side SPORTSMAN 00 (AB) 0 Logo, Polaris Star Decal, POLARIS, Front Cover (AA)(AB)(CA)(CB) Decal, POLARIS, Front Cover (AC) 0 Decal, Foot Brake 0 Logo, Seq., -00 (CB) 0 Urocal, SPORTSMAN (AA)(AB)(CA)(CB) 00 Decal, Override Switch, AWD 0 0 Decal, POLARIS, Side Panel (AA)(AC) Decal, POLARIS, Side Panel (AB) 00 0 Decal, Side Panel Stripe, LH (AA)(CA)(CB) Decal, Side Panel Stripe, RH (AA)(CA)(CB) 00 Decal, Passenger Warning 0 00 Decal, POLARIS, Rear (AA)(CA)(CB) Decal, POLARIS, Rear (AB)(AC) 00 Decal, Tire Pressure/Load 0 00 Decal, Discretionary Warning 00 Decal, Warning, General, CPSC /0 A

10 COOLING SYSTEM SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Cap, Pressure Filler, Coolant 0 Bracket, Filler, Coolant Rivet 00 Retainer, Hose 0 Screw Hose, Filler Neck 00 Clamp, 0000 Clamp, Hose AR Line, Fuel 0 Cap, Overflow, Drilled 0 Gasket, Overflow Cap Plug, Cap Tank, Surge 00 Fitting, Barbed, 0 Degree 000- Line, Fuel 000 Clamp, Hose 00 Clamp 00 Hose, Engine, Upper 0 00 Clamp, Hose 0 Nutsert 0 Washer, Flat 0 Washer, Spring Lock 0 0 Screw Hose, Guard -0 Bracket, Radiator, Upper 0 Screw Washer U-Clip 0 00 Sensor, Thermal 00 Radiator Grommet Screw 0 Valve, Drain 0 Bushing, Mount -0 Bracket, Radiator, Lower Screw Shroud, Fan 00 Clip, Wiring 0 0 Asm., Fan and Motor Screw 0 Hose, Engine, Lower 0 Connector, Tee 00 Clamp Hose 0 /0 A0

11 EXHAUST SYSTEM SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Nut, Nylok Washer, Flat 00 Bushing 0 Washer, Rubber Washer Bracket, Silencer, Frame 0 Dampener, Vibration Bolt, Carriage Silencer, Exhaust (If built before 0//0) Silencer, Exhaust (If built after 0//0) 0 Bolt 00 Seal, Exhaust 00 Spring, Exhaust 00-0 Pipe, Exhaust 0 Shield, Heat 0 Screw 0 Spring, Exhaust 0 Nut 00 Mount, Torque Stop 0 Nutsert Manifold 0 Shield, Heat, Exhaust Bolt 0 Washer, Flat /0 A

12 FUEL TANK SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Cap, Gas Tank (Incl. ) AR Line, Fuel Seal, Foam 00 Asm., Fuel Tank (Incl.,,) 00 Foil, Fuel Tank 0 Valve, -Way 0000 Clamp, Hose, Red AR Line, Fuel Nut, Fuel Valve 0 Knob, Fuel Valve 0 Screw 000- Sheath, Foil A 0-0 Bracket, Fuel Valve 0 Nutsert 00 Fitting, Fuel Outlet, Main 0 Fitting, Fuel Outlet, Reserve 00 Foil, Fuel Tank Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH 0 Washer, Flat 0 0 Washer, Spring Lock Bolt 0 Vent, Tank Gasket /0

13 ENGINE MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB A

14 ENGINE MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Pump, Fuel 0 Nut, Nylok Strap, Fuel Pump Mounting 0000 Clamp, Hose AR Line, Fuel 000 Filter Sheath, Foil 00 Kit, Short Block, ATV 0 0 NOTE: The Short Block assembly contains a crankcase assembly, cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization is required for warranty consideration. 0 Washer 0 00 Cable, Ground, Engine Screw AR Line, Fuel 00 Valve, Check 00 Fitting AR Line, Fuel 0 Nutsert Mount, Rubber -0 Bracket, Carburetor 0 Washer, Split Lock 0 0 Screw Screw Screw 0 Washer, Spring Lock 0 Nut, Flange Lock -0 Bracket, Mount, Top Washer Screw 000 Cable, Black Boot, Intake Clamp, Narrow Band 0 Mount, Rubber Bolt 0 Washer, Interlock 0 Washer, Flat 0 Bushing 0 Washer, Spring Lock Screw 00 Mount, Rubber, Top -0 Mount, Lower, Front 0 AR Washer, Flat 0-0 Bracket, Torque Stop /0 A

15 AIR BOX SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Filter, Precleaner Sleeve 00 Filter, Air Intake 00 Clamp, Narrow Band Sleeve Cover, Air Box Screw 0 Duct, Air Inlet Gasket, Intake Seal, Air Box Cover 0 Box, Air 0 Duct, Clutch Air Inlet 00 Clip Seal, Foam 00 Clamp, Hose Boot 00 Clamp, Narrow Band 00 Clamp, Hose AR Line, Breather 00 Clamp 0 Hose, Breather, Formed 00 Filter, Breather 00 Clamp, Hose Cap, End 0 Clip, Air Box Plug, Trap 00-0 AR Line, Fuel 000 Clamp, Hose 0 Foil, Air Box 0 Washer, Flat 0 Screw 0 Boot, Carb /0 B

16 FRONT DRIVE SHAFT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Asm., Drive Shaft (If built before /0/0) Asm., Drive Shaft (If built after /0/0) 0 00 Circlip 0 0 Joint, CV (Use w/0) Joint, CV (Use w/0) 00 Kit, Boot (Incl. Clamps and Grease) 0 Shaft(Incl.) 00 Kit, Cross and Bearing /0 B

17 REAR DRIVE SHAFT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Asm., Drive Shaft, Rear (Incl. -) 000 CV Joint 00 Clamp, Large 00 Grease, 0g 00 Boot 00 Clamp, Small 00 Grease, 0g 0 Joint, Plunging 00 Ring, Spring 0 Kit, Boot (Gear Side) 0 0 Kit, Boot (Wheel Side) /0 B

18 FRONT PROP SHAFT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Asm., Front Prop Shaft Pin, Spring 0 Yoke, Gear Case, Front 00 Kit, Cross and Bearing 00 Shaft, Bar 0 Yoke, Prop Shaft, Transmission 00 Fitting, Lubrication 0 O-Ring /0 B

19 REAR PROP SHAFT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Asm, Prop Shaft, Rear Pin, Spring 00 Yoke, Prop Shaft, Rear 00 Kit, Cross and Bearing 0 Shaft, Rear /0 B

20 FRONT STRUT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Nut, Nylok Washer 0 Spacer, Rubber Ball, Pivot, Top 0 Spacer Ball, Pivot, Bottom Retainer, Spring 00-0 Spring, Compression Bolt Washer, Flat 0 0 Hubstrut, LH Hubstrut, RH Bearing, Hubstrut 00 Ring, Retaining Asm., Front Brake Caliper, LH (See Front Brake Pg. B for Details) 000 Fitting, Lubrication 0 Washer, Spring Lock Screw Nut, Nylok 00 Clamp, Cable 0 Washer 0 Strut, Front 0 Bumper /0 B

21 FRONT WHEEL SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Bolt Disc, Brake 00 Stud 0 Hub, Wheel (If built before /0/0) Hub, Wheel (If built after /0/0) 0 Rim, Front, Chrome Tire (x-) Nut, Flange 00 Washer 0 Nut, Slotted 0 Cover, Dust 0 Pin, Cotter 0 Valve, Rim /0 B

22 FRONT BRAKE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Asm., Brake Caliper, LH (Incl. -,,0) 00 Asm., Brake Caliper, RH (Incl. -,,0) Screw, Socket Set 0 0 Caliper,Brake,LH Caliper,Brake,RH Kit, Front Brake Boot 0 Boot, Pin Seal 0 Kit, Piston and Seal (Incl. -) 0 Ring, Molded Square (.0) 00 Ring, Molded Square (.0 x.) Piston, Brake, Long 0 Kit, Front Brake Pad 0 Mount, Caliper 0 0 Boot, Bushing 00 Screw, Bleeder /0 B

23 CONTROLS - THROTTLE ASM./CABLE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 O-Ring Cover, Throttle Control O-Ring 00 Cable, Throttle 000 Asm., Throttle Control (Incl. ) 00 Asm., Throttle Clamp /0 B

24 CONTROLS - MASTER CYLINDER/BRAKE LINE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 00 Asm., Master Cylinder Boot, Brake Line, Rubber 0 Seal 0 Switch Screw 0 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 0 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 0 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 0 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 00 Line, Brake, Hand, Rear 0 Rivet 00 Clamp, Nylon 00- Conduit 0 Line, Brake, Left Front 00 Cable Tie 0 Screw 0 Line, Brake, Right Front 0 Fitting, Cross 00 Line, Brake, Pod 0 Bolt, Banjo /0 B0

25 STEERING POST SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Nut, Nylok 00 Fitting, Lubrication Bushing, Steering, Upper -0 Post, Steering -0 Bracket, Steering Post (If built before /0/0) Bracket, Steering Post (If built after /0/0) Bolt, Carriage (If built before /0/0) Bolt, Carriage (If built aftr /0/0) B Screw (If built after /0/0) Bushing Flangette 0 Bearing Nut Pin, Cotter 0 Washer, Flat /0

26 A-ARM/STRUT MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB E 00 Polaris Sales Inc Nut, FLEXLOC 00 Asm., Tie Rod 0 Bolt Boot, Seal, Rod End 00 Rod End Nut 00 Tie Rod 0 Nut, LH 00 Rod End, LH 0 0 Boot, Seal, Rod End 0 Washer, Flat Asm., Hubstrut (See Front Strut Pg. B for Details) Nut 0 Pin, Cotter 00 Joint, Ball Bracket, Ball Joint Screw 0 Boot, Rubber Nut, Castle 0 0 Screw Shield, CV Joint, LH Shield, CV Joint, RH Bushing, A-Arm, Long 00 Bushing 00 Shaft, A-Arm Kit, A-Frame, LH Kit, A-Frame, RH 00 Fitting, Lubrication 0 Washer, Spring Lock Screw Screw /0 B

27 HANDLEBAR and HEADLIGHT POD SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB B

28 HANDLEBAR and HEADLIGHT POD SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Bezel 0 Asm., Cluster Mount, Rubber Screw - Pod, Headlight, Upper, Gun Metal (AA)(CA)(CB) -0 Pod, Headlight, Upper, Yellow (AC) - Pod, Headlight, Upper, Spruce (AB) Screw 0 Spacer, Switch, LH 000 Switch, Handlebar -00 Grip, Handlebar 0 Plug Screw, Set Asm., Master Cylinder (See Controls - Master Cylinder/Brake Line Pg. B0 for details) -0 Bracket, Pod Mounting Screw 00 Knob, Adjusting 00 Rod, Adjusting 0 00 Asm., Headlamp Bulb, Headlight 0 O-Ring 000 Cable, Choke 0 00 Receptacle, Pod Mount, V 0 Harness, Light, Pod/Accy. Nut, Nylok Pod, Headlight, Lower, Black Met (AA)(CA)(CB) Pod, Headlight, Lower, Black (AB)(AC) 00 Clip, Cable Retaining Switch, Ignition (Incl. Key) Blank, Key, Series 000, 00, 00 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Blank, Key, Series 00, 00, 00, 00 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Cover, Key Cap 00 Sensor Screw 0 00 Nut, Choke 0 Clip, Screw -0 Tube, Handlebar Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) Kit, Handlebar Block (Incl. Blocks and,,) Block, Handlebar Retainer /0 B

29 DRIVE CLUTCH SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Clutch, One Way Drive 0 Washer, Brass Spacer 0 Nut, FLEXLOC Button, Clutch, Stemless 00 Pin, Roller Bearing 0 Nut, Jam 0 Cover, Bearing 0 0 Washer, Spring Lock Bolt 0 Spring, Clutch Roller and Bushing 0 Washer, Multilube Bolt, Shoulder Weight, Shift, 0- Asm., Drive Clutch, EBS, Wide (Incl. All Less,) 0 Washer, Thrust /0 C

30 DRIVEN CLUTCH SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Spacer, Driven 0 Bushing Asm., Driven Clutch, EBS (Incl. -,-) 0 Washer 00 Bushing 0 Ring, Retaining 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 0 Belt, Drive Screw Roller, Taper 0 Bearing Washer Bearing, Moveable, 0 Spring Ramp, Stationary 0 Spacer 0 Ring, Retaining /0 C

31 CLUTCH COVER SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Seal, Cover/Transmission 0 Cover, Clutch, Inner Kit, Inner Clutch Cover (Incl.,) Washer Screw 0 Duct, Clutch Outlet 000 Clamp, Narrow Band Boot, Duct 0 Screw -00 Cover, Clutch, Outer 0 0 O-Ring Plug 0 Decal, Automatic/EBS, Clutch 0 Decal, Warning, Clutch Cover Seal, Cover, Clutch, Outer Screw -0 Bracket, Retainer, Seal Seal, Cover, Inner /0 C

32 REAR WHEEL DRIVE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Cover, Dust, Hub 0 Pin, Cotter Washer, Cone 00 Rim, Rear, Chrome 0 Hub, Rear Whee Disc, Brake, Rear 00 Ring, Retaining 0 Bearing Carrier, Bearing, Wheel 0 00 Fitting, Lubrication Screw Tire, x- 00 Stud 0 Valve, Rim Nut, Flange 00 Nut, Castle /0 C

33 REAR SUSPENSION SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB C

34 REAR SUSPENSION SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Screw 0 Washer, Flat Bushing, Stabilizer Bolt 00-0 Arm, Stabilizer Bar Nut, Nylok 00 Rod, Linkage, Stabilizer Bar, Stabilizer Tube Bushing, Stabilizer Tube (If built before 0/0/0) Bushing, Stabilizer Tube (If built after 0/0/0) 0 Washer 00 Fitting, Lubrication 0 Washer, Flat Support, Stabilizer (If built before 0/0/0) Support, Stabilizer (If built after 0/0/0) Screw 00 Bushing 0 Bushing, A-Arm, Short (If built before 0/0/0) Bushing, A-Arm, Short (If built after 0/0/0) Screw 0 Washer, Spring Lock 00 Shaft, A-Arm, Short 0 0 Nut, Nylok 0-0 Strap, Rear Skid Plate Arm, Control, Upper, LH Arm, Control, Upper, RH Bushing, A-Arm, Long (If built before 0/0/0) Bushing, A-Arm, Long (If built after 0/0/0) 0 Washer, Flat Screw 0 Retainer, Spring 0-0 Spring, Compression Sleeve, Shock Protector 0 Cam, Adjusting, Spring 0 0 Shock, Rear Screw 00 Shaft, A-Arm Arm, Control, Lower, LH Arm, Control, Lower, RH Bushing, Bearing Carrier Washer, Lock Screw 0 Washer, Flat 0 0 Bushing, Control, Lower (If built before 0/0/0) Bushing, Control, Lower (If built after 0/0/0) Shield, LH Shield, RH 0 0 Screw Carrier, Wheel Bearing (If built before /0/0) Carrier, Wheel Bearing, LH (If built after /0/0) Carrier, Wheel Bearing (If built after /0/0) /0 C

35 ELECTRICAL/TAILLIGHT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Harness, Main Wire 0 Breaker, Circuit, 0 AMP 0 00 Asm., Taillight w/brake Light (Incl. -)(If built before /0/0) Asm., Taillight, V (Incl. -)(If built after /0/0) 00 Gasket, Taillight 000 Bulb, Taillight 00 Lens, Taillight 00 Screw, Taillight Screw -0 Strap, Battery Holddown Battery, 0 AMP 00 Backing, Taillight/Brake Light 00 Nut, Speed 000 Cable 00 Kit, Battery Bolt 00 Cable, Battery/Solenoid Screw Washer, Flat 0 Box, Battery 0 AR Tube, Battery Vent 0 0 Screw 0 Switch, Magnetic 00 Cable, Solenoid/Starter 00 Rectifier, Regulator Sink, Heat 00 Clip, Rosebud (Small) 00 Cable Tie 0 Screw /0 C

36 REAR MASTER CYLINDER/FOOT PEDAL SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Screw 0 Reservoir, Brake, Rear Nut 0000 Clamp, Hose 0 Hose, Reservoir 0-0 Mount, Brake Screw 0 Pin, Cotter Washer 0 Bushing, Pivot, Pedal 0-0 Rod, Brake 00 Spring 00 Master Cylinder, Brake, Rear Screw 00 Spring, Gear Selector Lockout 0 Seal 0 Bolt, Banjo 0 Line, Rear Brake, Foot /0 C

37 REAR CALIPER SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB,,,,, 0 0 Asm., Brake Caliper Screw 0 Washer, Spring Lock 0 Washer, Flat Carrier, Bearing 0 Bracket, Caliper 000 Clamp, Nylon Rivet Line, Brake, Rear, Hand (See Controls - Master Cylinder/Brake Line Pg. B0, Ref. ) 0 Line, Brake, Rear, Foot 0 Screw 0 Clip, Retaining, Dual 0 Kit, Anvil Body 0 Fitting,Bleed, Compact 00 Kit, Slide Bolt 0 Kit, Seal 0 Kit, Piston and Seal 0 Kit, Brake Pad /0 C

38 GEAR SELECTOR SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 00 Cover 0 Screw 00 Knob, Gear Selector 0 Mount, Gear Selector Screw Nut, Nylok 0 Asm., Linkage Spacer, Shifter 0-0 Selector, Gear 0 Bolt Screw /0 C0

39 FRONT HOUSING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Asm., Front Gearcase (Incl. -,-0,-) 0 Gearcase (Incl.,,) Asm., Drain Plug (Incl.,) Asm., Cover Plate (Incl.,,) Asm., Race/Output Hub (Incl.,,,) Asm., Clutch (Incl. -,) Kit, Minor Repair (Incl.,,,) Asm., Roll Cage (Incl.,) Cover, Output O-Ring Insert Coil Kit, Shim Set (Incl. Shims) Bearing, Roller Ball Hub, Race/Output, Male Pin, Dowel Bearing, Roller Ball 0 Clutch Housing/Ring Gear Spring Kit, Roll Ring, Retaining Bushing Hub, Race/Output, Female Bushing 000- AR Line, Fuel 00 Clamp, Hose 0 Screw Clamp, Hose O-Ring Seal Kit, Bolt Cover, Input Bearing, Roller Ball Shaft, Pinion, T Bushing Gearcase, LH Seal, Oil 0 Plug, Oil Fill 0 Washer, Spring Lock Screw Plug, Oil Drain Washer Bearing, Needle, Roller Thrust Roll Cage, Aluminum Plate Armature /0 C

40 TRANSMISSION MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Asm., Main Gearcase (See Gearcase Pg. C for Details) 0 Nut, Flange, Lock Screw 000- AR Line, Fuel 00 T-Fitting 00 Clip 000 Clamp, Hose Nut, Flange Screw Washer, Flat 0-0 Mount, Rear Transmission 0 Washer, Spring Lock Bolt -0 Mount, Transmission Screw 0-0 Mount, Rear Engine /0 C

41 GEARCASE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB C

42 GEARCASE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Nut Screw Cover Pawl, Detent O-Ring Shaft, Shift Seal Gear, T Plug, Oil Fill 0 Tube, Vent 0 Bearing 0 Chain, Silent 0 Shaft, Input 0 Bearing Pipe, Knock Cover, LH Seal 0 Drum, Shift Fork, Shift 0 Pin, Dowel 0 Rail, Shift Shaft Plate, Park 00 Engagement Dog Spring, Wave Engagement Dog 0 Ring, Retaining Washer Gear, T Bearing, Needle 0 Shaft, Reverse Sprocket, T Washer Gear, T Gear, 0T 0 Gear, T 0 Screw 0 Cover, Bearing 0 Ring Spacer 0 0 Bearing, Ball 0 Shaft, Pinion, 0T Washer, Thrust Sprocket, T/T Gear, T Shaft, Output, Main, Rear Button, Thrust AR Shim AR Shim Cover, Output, Front 0 Screw Plug Washer Shaft, Output, Front Chain, Silent Sprocket, T Bushing Lockout, Park Gearcase, Main Washer 0 O-Ring Gear, T Disc, Lockout 0 Star, Detent 0 O-Ring 0 Spring, Compression Switch Ring, Retaining 0 Bellcrank Asm., Main Gearcase /0 C

43 REAR GEARCASE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Asm., Gearcase, Rear Cover, Output, LH Screw Tube, Vent Washer Plug Seal AR Shim Button, Thrust Pipe, Knock 0 Bushing Shaft, Pinion, 0T Bearing, Ball O-Ring Cover, Input Seal 0 Gearcase, Housing, Rear Bearing, Ball Gear, T AR Shim /0 D

44 REAR GEARCASE MOUNTING SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Screw 0 Washer, Flat 00 Nut, FLEXLOC Screw 0 Washer, Spring Lock /0 D

45 CRANKCASE SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Seal, Flanged (If built before 0/0/0) Seal, Flanged (If built after 0/0/0) Bearing, Ball Bushing Bearing, Ball 00 Plug 0 Asm., Crankcase (Incl.,-) Bearing 0 Ring, Retaining Seal, Oil 0 0 Kit, Cover (Incl. Gasket) Gasket, Cover 0 Screw 0 Seal (If built before 0/0/0) Seal (If built after 0/0/0) 0 Bearing, Main Journal 00 Plug, Magnetic Washer, Copper Screw Screw 00 Pin, Dowel 0 Baffle 0 Screw 0 Screw 00 Pickup, Oil 0 O-Ring /0 D

46 CRANKSHAFT and PISTON SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 00 Kit, Piston (Incl.,,) Circlip, Piston Pin, Piston Key, Woodruff 0 Gear, Crankshaft Ring, Oil Control Ring, Iron Ring, Chrome Kit, Piston Ring (Incl. Control,Iron, and Chrome Rings) 0 Asm., Crankshaft (W/O Gear) 0 Asm., Crankshaft w/gear (Incl.,) Shaft, Balance 0 Key, Woodruff 0 0 Gear, Balance Shaft (If built before //0) Gear, Balance Shaft (If built after //0) Washer Screw /0 D

47 CYLINDER and CYLINDER HEAD SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 D

48 CYLINDER and CYLINDER HEAD SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Screw Cover, Breather 0 Reed w/gasket Screw 0 Cover, Rocker Seal Screw Gasket, Exhaust Manifold (See Exhaust System Pg. A, Ref. 0) 0 0 Screw 0 Head, Cylinder Guide, Valve Gasket, Head 0 Kit, Cylinder (Incl. ) Gasket, Base 0 Plug Asm., Carburetor 00 Clamp, Hose Screw Adapter, Carburetor 0 00 Spark Plug, RCYC Screw Cover, Thermostat 00 Thermostat O-Ring 00 Switch, Temperature 0 Fitting /0 D

49 CARBURETOR SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB D

50 CARBURETOR SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 00 Ring 00 E-Ring 0 Needle, Jet 0 Ring 0 Diaphragm Needle, Jet (P-) 0 Screw 00 Washer, Spring Asm., Jet Block 0 00 Washer 0 Jet, Main (#) 0 Cap 0 Seal 0 Packing E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 0 00 Screw 00 Asm., Float Body 0 Screw 0 Asm., Float 0 Screw 0 Valve, Needle (.) 0 O-Ring Jet, Pilot (#) 0 O-Ring 0 Washer 0 0 Spring 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring Valve, Throttle (00) Spring 0 Ring Screw Asm., Throttle Shaft 0 0 Guide, Cable 0 Screw 0 Cover 0 O-Ring Holder, Guide 0 Spring Asm., Plunger 0 Jet, Air (#0) 00 Spring 0 00 Asm., Cover 0 Screw Asm., Carburetor (Incl. -)(AA)(AB)(AC) Asm., Carburetor (Incl. -)(CA)(CB) /0 D

51 INTAKE and EXHAUST SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 0 Asm., Rocker Arm 0 Pushrod 00 Kit, Camshaft (Incl. ) Plate, Thrust Screw 0 00 Gear, Camshaft, Inner (CA)(CB) Gear, Camshaft, Inner (AA)(AB)(AC) 0 Spring, Compression 00 Gear, Camshaft, Outer (CA)(CB) Washer, Spring 0 Screw Lifter, Valve Valve, Exhaust Valve, Intake Seal, Valve Guide 0 Spring, Valve Retainer, Spring 00 Lock, Valve Stem /0 D

52 OIL DIPSTICK SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 00 Asm., Dipstick 00 Tube, Oil Fill Screw 0 Clamp 0 O-Ring /0 D0

53 WATER PUMP SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Shaft, Oil/Water Pump 0 Bearing Gear, Water/Oil Pump Impeller Washer, Flat 0 Nut, Nylok 0 Screw Screw 00 Cover 0 0 O-Ring 00 Seal, Water Pump /0 D

54 OIL PUMP SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Kit, Oil Pump (Incl.,, from Water PumpPg.D,Ref.,,) 000 Filter, Oil 00 Nipple, Oil Filter 0 Screw Housing, Oil Pump 00 Gerotor Pin, Dowel 0 Spring 00 Washer Screw /0 D

55 MAGNETO SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Holddown, Wire 000 Asm., Stator Screw Screw 00 Asm., Flywheel 0 Washer 0 Nut 0 O-Ring 0 Housing, Stator 0 Cover, Sound 0 Cover, Outer O-Ring 0 0 Screw 0 Plug 00 Controller, Ignition 00- Wire, Ignition 00 Cap /0 D

56 STARTING MOTOR SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Screw 00 Starter 0 Washer, Thrust 00 Bendix Washer, Lock 0 Nut /0 D

57 TOOL KIT SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB 0 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the PartSmart, which is updated monthly. Kit, Tool (Incl. -) 0 Gauge, Tire Pressure Screwdriver Wrench, -0 Open Wrench, / x / Open Wrench, Plug Puller, Spark Plug (Wrench Handle) Pouch, Tool Kit Owner s Manual, 0 Sportsman 00 0 Wrench, Torx /0 E

58 REAR RACK MOUNTING (If Built After /0/0) SPORTSMAN 00 A0CHAA and SPORTSMAN 00 A0CHAB and SPORTSMAN 00 A0CHAC and SPORTSMAN 00 A0CHCA and SPORTSMAN 00 A0CHCB Extender, Rack, Rear (Incl. )(AA)(CA)(CB) Extender, Rack, Rear (Incl. )(AC)(AB) Screw Screw 0-00 Asm., Rack, Rear (Incl. Ref. and Warning Decal) 0 Decal, Reflector, Red 0 Spacer Bolt -0 Bracket, Silencer, Frame 0 Washer, Flat 0 Nut, Nylok 00 Nut, Chimney 0-0 Support, Rear Rack 0 Screw /0 E

59 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /0

60 Changed pages in 0 A cover toc x B x C D E F G 0